Apparatus and method of forming a custom earpiece

ABSTRACT

Embodiments of the present disclosure generally relate to custom-fit in-ear audio devices. The custom-fit earpieces disclosed herein may include features providing superior retention in a user&#39;s ear while also maintaining desirable comfort and sound quality. The superior retention is generally provided by a curable filler disposed in a bladder that is deformed to conform to the shape of a user&#39;s outer ear as the filler material is cured. It has been found that a desired comfort level and sound quality can be achieved in a custom-fit earpiece by physically separating or at least partially decoupling the audio output member from other portions of the earpiece that are designed to enable the retention of the custom-fit earpiece within the user&#39;s ear. In some configurations, one of the portions of the custom-fit earpiece that is designed to enable the retention of the custom-fit earpiece within the user&#39;s ear includes a curable filler material that is disposed within a bladder that is coupled to a portion of the custom-fit earpiece.

BACKGROUND Field

Embodiments of the present disclosure generally relate to custom-fitearpieces and methods for customizing an earpiece for use in a user'sear.

Description of the Related Art

Audio devices allow users to receive audio content or audio informationfrom various media sources, such as internet, video players, gamingdevices, music playing platforms or other types of audio generatingdevices. Typical portable in-ear audio devices may include varioustethered and wireless headphones or other similar devices. Some commontypes of in-ear audio devices are in-ear monitors that provide anenhanced listening experience for studio recording, stage performance,and audiophile listening. To listen to recorded music, in-ear monitorsmay be hard-wired or wirelessly connected to a music player to listen torecorded music. In-ear monitors are superior to loudspeakers in thatthey facilitate a personalized mix of audio sources. In-ear monitors mayreduce, eliminate or control ambient noise, including crowd and stagenoise.

It is generally preferable to customize an in-ear audio device to auser's ear, so that the in-ear audio device is easily retained in theuser's ear, and so that surrounding ambient noise can be eliminated orcontrolled. Traditionally, custom-fit in-ear audio device have used awax-molding process to tailor the in-ear audio device to the uniqueshape of a user's ear. Although this wax-molding process can achieve awell-fitting custom in-ear audio device for a user, the process can betime-consuming and expensive. The process may require the user to travelto a location where a business can perform the wax molding of the user'sear. Then the user must wait multiple days until the custom in-ear audiodevice can be produced based on the wax molding and then sent to theuser.

Therefore, there is a need for an improved custom-fit in-ear audiodevice and method of customizing the in-ear audio device that overcomesthe deficiencies described above.

SUMMARY

Embodiments of the present disclosure generally relate to an in-earaudio device, or earpiece, and methods of customizing the earpiece foruse in a user's ear. The earpiece may include a curable filler disposedin a bladder that can be deformed to conform to the shape of a user'sear. The earpiece and method of customizing the earpiece disclosedherein will improve a user's experience for customizing an earpiece to auser's ear and subsequent use by separating an audio output member ofthe earpiece from the portion of the earpiece including the curablefiller. This separation enables an improved mechanical fit of theearpiece in the user's ear and also prevents the deformation of thebladder when the earpiece is customized to the user's ear from placingundesirable amounts of stress on the audio components in the audiooutput member, which can reduce sound quality.

Embodiments of the present disclosure may include an earpiece forproviding sound to a user comprising a first body including a bladderand a curable filler disposed within the bladder, and an audio outputmember comprising a sound tube. The audio output member may be coupledto the first body at a flexible connection that is positionedtherebetween. The flexible connection may also be positioned at a firstlocation on the first body, and the audio output member is positionedoutside of an exterior surface of the bladder.

Embodiments of the present disclosure may also include a method ofcustomizing an earpiece to an outer ear of a user comprising placing anaudio output member comprising a sound tube in an ear canal of a user,placing a first body in a cavum conchae of an outer ear of the user,wherein the first body comprises a bladder and a curable filler disposedin the bladder, the audio output member is coupled to the first body ata flexible connection that is positioned therebetween, the audio outputmember is coupled to the first body at a first location, and the audiooutput member is located outside of an exterior surface of the bladder,and applying a force to the first body to press the first body againstthe cavum conchae, wherein the force causes the first body to deform.

Embodiments of the present disclosure may further include an earpiecefor providing sound to a user comprising a first body comprising abladder, an outer body disposed around the bladder, and a curable fillerdisposed within the bladder, wherein the outer body includes a centralportion extending around the bladder, the bladder consists of a firstportion and a second portion, the first portion disposed entirely on afirst side of the central portion of the outer body and the secondportion disposed entirely on the second side of the central portion ofthe outer body, the second portion comprises at least 40% of a totalvolume of the bladder, an audio output member comprising a sound tube,wherein the audio output member is coupled to the outer body at aflexible connection that is positioned therebetween, the flexibleconnection is positioned at a first location on the outer body, and anorientation of the audio output member is adjustable in one or moredimensions relative to a stationary first body.

Embodiments of the present disclosure may also include a method offorming a customized earpiece, comprising positioning an earpiece withina portion of an ear of a user, wherein the earpiece comprises a firstbody that comprises an outer body supporting a bladder, and an audiooutput member that is coupled to the outer body of the first body at afirst location. The process of positioning the earpiece may includepositioning a sound tube of the audio output member in an ear canal ofthe ear of the user, and the first body in a cavum conchae of the ear ofthe user, urging the first body against the cavum conchae, and curing acurable filler material disposed within the bladder while urging thefirst body against the cavum conchae. The process of urging the firstbody against the cavum conchae causes the bladder and the outer body todeform and an angular orientation of the audio output member relative tothe ear canal to adjust. The process of curing the curable fillermaterial may include delivering one or more wavelengths ofelectromagnetic radiation to the curable filler material from an energysource to cause the bladder and the outer body to be fixed in thedeformed state.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentdisclosure can be understood in detail, a more particular description ofthe disclosure, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlyexemplary embodiments and are therefore not to be considered limiting ofits scope, and may admit to other equally effective embodiments.

FIG. 1A is an exploded sectional view of an earpiece, according to oneembodiment.

FIG. 1B is a partial side cross-sectional view of the earpiece of FIG.1A, according to one embodiment.

FIG. 1C is a cross-sectional view of the audio output member of theearpiece, according to one embodiment.

FIG. 1D is a perspective view of the earpiece, according to oneembodiment.

FIG. 1E is a perspective top view of the earpiece showing an azimuthillustrating a first orientation of an audio output member relative to afirst body of the earpiece, according to one embodiment.

FIG. 1F is a perspective side view of the earpiece showing an altitudeillustrating a second orientation of an audio output member relative toa first body of the earpiece, according to one embodiment

FIG. 2A is an exemplary illustration of a human outer ear.

FIG. 2B is a perspective view of the earpiece of FIG. 1A disposed withina portion of the user's outer ear before a user customizes the earpieceto conform to the shape of the user's outer ear, according to oneembodiment.

FIG. 2C is a perspective view of the earpiece of FIG. 1A disposed withina portion of the user's outer ear after a user customizes the earpieceto conform to the shape of the user's outer ear, according to oneembodiment.

FIG. 2D is a perspective view of the earpiece further illustrating theeffects of customizing the earpiece to a user's ear, according to oneembodiment.

FIG. 3 is a process flow diagram of a method for customizing theearpiece of FIG. 1A to a user's ear, according to one embodiment.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements and features of oneembodiment may be beneficially incorporated in other embodiments withoutfurther recitation.

DETAILED DESCRIPTION

Embodiments of the present disclosure generally relate to custom-fitin-ear audio devices, also referred to herein as custom-fit earpieces orsimply earpieces. The following discloses embodiments of custom-fitearpieces that include features providing superior retention in a user'sear while also maintaining desirable comfort and sound quality. Thesuperior retention is generally provided by a curable filler disposed ina bladder that is deformed to conform to the shape of a user's outer earas the filler material is cured. The retention of the custom-fitearpiece in the user's ear is also enhanced from an audio output memberthat is spaced apart from the bladder allowing the audio output memberto be positioned at a desirable depth within the user's ear canal. Ithas been found that a desired comfort level and sound quality can beachieved in a custom-fit earpiece by physically separating or at leastpartially decoupling the audio output member from other portions of theearpiece that are designed to enable the retention of the custom-fitearpiece within the user's ear. In some configurations, one of theportions of the custom-fit earpiece that is designed to enable theretention of the custom-fit earpiece within the user's ear includes thecurable filler material that is disposed within the bladder. The comfortlevel of the custom-fit earpiece described herein is enhanced becausethe audio output member can move independently or relative to theportion of the earpiece that includes the curable filler, thus allowingthe audio output member to adjust to and comfortably fit within a givenuser's ear canal. The sound quality of the custom-fit earpiece may alsobe enhanced because the audio output member is spaced apart from theregion of the custom-fit earpiece that contains the curable filler sincethe deformation of the curable filler during the customizing processwill place a significant mechanical stress on any audio components(e.g., sound tube) of the audio output member disposed in the bladderwith the curable filler due to the pressure applied to the bladder andcurable filler material during the curing process.

FIG. 1A is an exploded sectional view of an earpiece 100, according toone embodiment. FIG. 1B is a partial side cross-sectional view of theearpiece 100, according to one embodiment. In general, the earpiece 100described herein will include various types of in-ear audio devices,such as wired or wireless in-ear monitors, wired or wireless earbuds,hearing aids, and any other wearable devices that can be used toprovide, block, and/or otherwise control sound received by a user's ear.

The earpiece 100 includes a first body 110, an audio output member 150,and a flexible tail 135. The first body 110 includes a curable filler116 that can be deformed and then cured so that the deformed curablefiller 116 will retain the shape of at least a portion of a given user'sear during a curing process, which is described further below. The audiooutput member 150 includes audio components (e.g., audio driver andsound tube) that provide audio to the user's ear during use of theearpiece 100. The first body 110 is connected to the audio output member150 at a first connection location 111 on the first body 110. The audiooutput member 150 is configured to move independently in threedimensions relative to a stationary first body 110 enabling the audiooutput member 150 to comfortably fit within the user's ear canal duringuse of the earpiece 100.

The first body 110 can include an outer body 114 that is disposed aroundat least a portion of a bladder 115 that contains the curable filler116. The outer body 114 can be formed of a thermoplastic material, suchas a silicone or other similar flexible polymeric material. The outerbody 114 can include a ring 114A and a concave feature 114B (e.g., acup). The concave feature 114B can have a thickness 114T from about 1 mmto about 10 mm, such as about 2 mm. The bladder 115 can be disposed in acavity 113 formed by the ring 114A and the concave feature 114B. In someembodiments, the ring 114A can seamlessly connect to the concave feature114B. In some embodiments, the curable filler 116 is a curablephotopolymer (e.g., a UV-curable polymer, such as a urethane acrylate orsilicone) that is able to retain a desired fixed shape after performinga curing process. In other embodiments, the curable filler 116 may beanother type of curable filler, such as a chemically curable filler(e.g., a reactive epoxy, urethane acrylate, or silicone). In someembodiments, the curable filler 116 can have a hardness from about 20Shore A to about 50 Shore A, such as about 30 Shore A after a curingprocess has been performed.

In some embodiments, the bladder 115, which is configured to enclose andretain the curable filler material 116, can include one or more layersof material. In some embodiments, the bladder 115 will include one ormore layers of material that are able to allow desired wavelengths ofelectromagnetic radiation (e.g., UV wavelengths) to pass therethrough sothat the enclosed curable filler material 116 can be cured during thecuring process by radiation provided from an electromagnetic source thatis positioned outside of the bladder 115. In one embodiment the bladder115 can be formed of a single layer of material. In some embodiments,the bladder 115 can include an inner layer that is formed from aflexible polymer, such as a polyurethane material. In some embodiments,the bladder 115 can further include an outer layer that can be formed ofa flexible polymer, such as a thermoplastic or thermoplastic blend. Inone embodiment, the bladder 115 is made from a polymeric material thathas a durometer of between about 10 Shore A and 80 Shore A.

Furthermore, in some embodiments (see e.g., FIG. 1A), the outer layer ofthe bladder 115 can be formed as part of the outer body 114, such asconcave feature 114B that has a thickness 114T. Although, the curablefiller 116 can be designed to remain relatively soft after curing (e.g.,having a hardness around 30 Shore A), the curable filler 116 can berigid enough to resist the tendency of the bladder 115 and outer body114 to return to its original shape, such as its shape prior toperforming the curing process described below. In some embodiments, theoriginal shape of the first body 110 is a spherical shape that has adiameter from about 6 mm to about 20 mm, such as about 13 mm.

In some embodiments, the earpiece 100 can further include an energysource 120 (see FIG. 1A). The energy source 120 can include a housing122 and an energy emitting source 121 disposed in the housing 122. Forexample, FIG. 1A shows an energy emitting source 121 emittingelectromagnetic radiation, light L towards the bladder 115 and curablefiller 116. In some embodiments, the energy source 120 can be a lightsource, such as a UV light source. For example, in one embodiment, a UVlight source that emits radiation at a wavelength from about 345 nm toabout 420 nm, such as about 365 nm can be used to cure the curablefiller 116.

The energy source 120 may be located outside (see FIG. 1A) of thebladder 115 or inside of the bladder 115 (see e.g., alternate lightsource 120A in FIG. 1B). As noted above, in some embodiments in whichthe energy source 120 is disposed outside of the bladder 115, thematerials used to form the bladder 115 are transparent to the radiationemitted by the energy source 120. In some embodiments, some portions ofthe outer body 114, such as the concave feature 114B, are configured tobe substantially opaque to the energy emitted by the energy source 120,so that the energy emitted by the energy source 120 is received by thecurable filler 116 material disposed within the cavity 113 but nottransmitted through the outer body 114 and to a portion of the user'sbody, such as a user's ear. In one embodiment, carbon black can be addedto at least some portions of the outer body 114 that is formed from asilicone material to make the outer body 114 opaque to UV light.

In some embodiments in which the energy source is disposed inside thebladder 115, the outer body 114 and/or materials used to form thebladder 115 can be configured to be substantially opaque to the energyemitted by the energy source 120, so that the energy emitted by theenergy source 120 is not transmitted through the earpiece 100 and to aportion of the user's body, such as a user's ear. In one embodiment,carbon black may be added to an outer layer of the bladder 115 to makethe outer layer of the bladder 115 opaque to UV light.

In some embodiments, during the curing process the energy source 120 canbe activated by a button or other input (not shown) on the earpiece 100which causes a battery (not shown) disposed within the energy source 120or the interior region 152 (FIG. 1C) of the earpiece 100, to power thelight source disposed within the energy source 120. In otherembodiments, the energy source 120 can be activated by a remote signal,such as a wired or wireless signal that is received by a wired orwireless transceiver (not shown) contained within the earpiece 100, suchas within the I/O devices 162 described below. For example, in oneembodiment, the energy source 120 is connected to the wirelesstransceiver that is adapted to receive a wireless signal (e.g., aBluetooth signal) from an external electronic source (e.g., cell phone)that can cause the battery within the earpiece 100 to energize theenergy source 120 to initiate the curing process.

The flexible tail 135 is connected to the first body 110 at a secondlocation 112 on the first body 110. The flexible tail 135 extendslengthwise from a base 136 to an end 137. In one embodiment, theflexible tail 135 has a circular cross-section. The diameter of thecross-section may be uniform as the flexible tail 135 extends along itslength. In one embodiment, the flexible tail 135 has a thickness (e.g.,diameter) from about 1 mm to about 3 mm, such as about 2 mm.Furthermore, in one embodiment, the flexible tail 135 has a length fromthe base 136 to the end 137 from about 10 mm to about 30 mm, such asabout 20 mm. The flexible tail 135 can be positioned against a portionof the user's ear to further enhance retention of the earpiece 100 inthe user's ear. The flexible tail 135 can be formed as part of the outerbody 114, and thus may be formed from a flexible polymer, such as athermoplastic (e.g., silicone) or a thermoplastic blend. In oneembodiment, the outer body 140 is made from a polymeric material thathas a durometer of between about 10 Shore A and 80 Shore A.

The audio output member 150 includes audio components that provide audioto the user's ear during use of the earpiece 100. The audio outputmember 150 is configured to move relatively independently in threedimensions relative to the stationary first body 110 enabling the audiooutput member 150 to comfortably fit within the user's ear canal duringuse of the earpiece 100. The audio output member 150 is located outsideof exterior surface 115A of the bladder 115, and in some embodiments, isattached to the ring 114A. Locating the audio output member 150 outsidethe bladder 115 prevents the customization process of the earpiece 100(i.e., deforming the bladder 115) from damaging one of the audiocomponents of the audio output member 150, such as the sound tube 166described below. Furthermore, locating the audio output member 150outside of the bladder 115 allows the audio output member 150 to deflectrelative to the first body 110 including the bladder 115, so that theaudio output member 150 can adjust to comfortably fit within a user'sear canal while the first body 110 including the bladder 115 can bepositioned against the user's outer ear. It has been found that user'sear canals can extend in drastically different directions from one userof an in-ear audio device to the next, so having the orientation of theaudio output member 150 decoupled from first body 110 can help to ensurea comfortable and appropriate fit for each user. Additional detailsregarding the configuration of the audio output member 150 is providedin relation to FIG. 1C below.

FIG. 1C is a cross-sectional view of the audio output member 150 of thecustom-fit earpiece 100, according to one embodiment. The audio outputmember 150 includes an outer shell 151 and an ear tip 155 coupled to theouter shell 151. The audio output member 150 also includes an interiorregion 152 that is disposed within the outer shell 151. The outer shell151 can also include a base 157 at the opposite end of the outer shell151 from the ear tip 155. In some embodiments, the outer shell 151 canhave a cylindrical shape with a diameter from about 6.5 mm to about 10.5mm, such as about 8.5 mm.

The ear tip 155 includes an end 155E through which sound is projectedtowards the user's ear drum. The ear tip 155 can be configured tocontact the user's ear canal during use of the earpiece 100. The ear tip155 can be formed of a soft material, such as silicone or foam material.

The interior region 152 can include components for generating audiooutput. For example, the interior region 152 can include an audio driver165 and a sound tube 166 coupled to the audio driver 165. The audiodriver 165 is used to generate an audible output (e.g., one or moreaudio signals at frequencies >200 Hz) that is provided to the user ofthe earpiece 100 through the sound tube 166. The sound tube 166 can bepositioned to project the audible output from the audio driver 165 intothe user's ear canal. The sound tube 166 can extend from the audiodriver 165 to an end 166E near the end 155E of the ear tip 155. Althoughonly one audio driver 165 is shown, in some embodiments, the earpiece100 may include two or more audio drivers and/or two or more sound tubesthat can be used to produce the high-quality audio output commonlyassociated with some types of earpieces, such as in-ear monitors.

The interior region 152 can further include one or more electroniccomponents for generating the audio output. For example, the interiorregion 152 can include a processing unit 163 coupled to input/output(I/O) devices 162, and to a memory unit 164. Memory unit 164 can includedata (e.g., audio data) and one or more applications stored therein.Processing unit 163 may be any hardware unit or combination of hardwareunits capable of executing software applications and processing data,including, e.g., audio data. For example, processing unit 163 could be acentral processing unit (CPU), a digital signal processor (DSP), anapplication-specific integrated circuit (ASIC), a combination of suchunits, and so forth. Processing unit 163 is configured to executesoftware applications, process audio data, and communicate with I/Odevices 162 among other operations.

I/O devices 162 are also coupled to memory unit 164 and may include aplurality of electrical components capable of receiving various inputsand capable of providing various desirable outputs. For example, I/Odevices 162 may include one or more transceivers configured to establishone or more different types of wireless communication links with othertransceivers residing within other computing devices (not shown). Agiven transceiver within I/O devices 162 could establish, for example, aWi-Fi communication link, a Bluetooth® communication link, or a nearfield communication (NFC) link, among other types of communicationlinks. In some embodiments, the I/O devices 162 may further include anantenna (not shown), which is coupled to or disposed within audio outputmember 150 and also electrically coupled to a wireless transceiver thatis configured to establish a wireless communication link with othertransceivers residing within other external computing devices (notshown). I/O devices 162 may also include inputs (e.g., a 3.5 mm audioinput jack) to receive audio input from an external wired audio source(not shown). I/O devices 162 may also include other inputs, such as oneor more buttons or switches. I/O devices 162 may also include one ormore outputs, such as status indicators (e.g., LEDs or speakers) oroutputs (e.g., control relays) for controlling other outputs (e.g.,energy source 120) in the earpiece 100. I/O devices 162 will alsoinclude one or more signal processing support components, signalfiltering components (e.g., low pass and/or high pass filters) andcomponents used to enable the delivery of an audible output from thedriver 165 (e.g., signal amplifiers).

Memory unit 164 may be any technically feasible type of hardware unitconfigured to store data. For example, memory unit 164 could be a harddisk, a random access memory (RAM) module, a flash memory unit, or acombination of different hardware units configured to store data.Software application(s) within memory unit 164 can include program codethat may be executed by processing unit 163 in order to perform variousfunctionalities associated with the earpiece, such as playing oradjusting audio output and activating the energy source 120.

FIG. 1D is a perspective view of the earpiece 100 prior to performingthe curing process described below, according to one embodiment. Theearpiece 100 includes the first body 110, which includes the outer body114 that can be disposed around at least a portion of the bladder 115.The bladder 115 can include a first portion 115 ₁ and a second portion115 ₂. The ring 114A of the outer body 114 can include a central portion114C that divides the outer body 114 (e.g., bisects the outer body 114)in an angular direction (i.e., the direction in which the ring 114A ofthe outer body 114 extends around the bladder 115). For example, if theouter body 114 has a circular shape when viewed from the side as shownin FIG. 1B, then the central portion 114C can be a circumference of acircle formed around the bladder 115. The first portion 115 ₁ isdisposed on a first side 114 ₁ of the central portion 114C. The secondportion 115 ₂ is disposed on a second side 114 ₂ of the central portion114C. The first portion 115 ₁ of the bladder 115 can be configured to bepressed by a user's hand when the user customizes the earpiece 100 tothe user's ear during the curing process as described below in referenceto FIG. 3. The second portion 115 ₂ can be configured to be pressedagainst a user's ear when the user customizes the earpiece 100 to theuser's ear as described below in reference to FIG. 3.

In some embodiments, the first portion 115 ₁ and the second portion 115₂ can be substantially similar in size. For example, in someembodiments, the first portion 115 ₁ can have a volume within 20% of thevolume of the second portion 115 ₂, such as within 10% of the volume ofthe second portion 115 ₂. In other embodiments, the first portion 115 ₁and the second portion 115 ₂ can be nearly identical in size, such aswhere the volume of the first portion 115 ₁ is within 5% of the volumeof the second portion 115 ₂, such as within 1% of the volume of thesecond portion 115 ₂. Furthermore, in some embodiments the bladder 115can have a spherical shape prior to performing the curing processdescribed below in reference to FIG. 3, where the first portion 115 ₁ isa first hemisphere of the sphere, and the second portion 115 ₂ is asecond hemisphere of the sphere.

The audio output member 150 can be coupled to the first body 110 throughthe outer body 114. Furthermore, the audio output member 150 can becoupled to the outer body 114 at the central portion 114C, so that thesecond portion 115 ₂ is disposed on one side of the central portion 114C(i.e., the second side 114 ₂ of the central portion 114C) enabling theposition and orientation of the audio output member 150 to be adjustedrelative to a stationary second portion 115 ₂. Moreover, in someembodiments the second portion 115 ₂ has a volume that is at least 40%of the total volume of the bladder 115, such as at least 50% of thetotal volume of the bladder 115, such as at least 60% of the totalvolume of the bladder 115. It is contemplated that when the secondportion 115 ₂ represents a larger portion of the total volume of thebladder 115, the position and orientation of the audio output member 150may be more easily adjusted relative to the first body 110 when comparedto similar embodiments of the earpiece where the second portion 115 ₂represents a smaller portion of the total volume of the bladder 115.

The position and orientation of the audio output member 150 can beadjusted in three dimensions relative to a stationary first body 110allowing the audio output member 150 to comfortably fit within a user'sear canal during use of the earpiece 100. Ear canals of different peoplecan take significantly different routes from the entrance of the earcanal towards the user's ear drum, so this three-dimensional flexibilityenables a comfortable fit of the audio output member 150 in a broadspectrum of potential users while allowing the first body 110 to beretained within portions of the user's outer ear, such as the conchaecavum as described below in reference to FIGS. 2A-2C. Thethree-dimensional movement of the audio output member 150 relative tothe stationary first body 110 is greater before the curable filler 116in the bladder 115 is cured, but in many embodiments there may still besome three dimensional flexibility of the audio output member 150 afterthe curable filler 116 has cured during the curing process.

The three-dimensional movement of the audio output member 150 relativeto a stationary first body 110, which occurs when the first body 110 isdeformed during the curing process and when the earpiece 100 is insertedand reinserted into a user's ear after the curing process has beenperformed, may be described in terms of two angles, an azimuth AZ (seeFIG. 1E) and an altitude ALT (see FIG. 1F).

FIG. 1E is a perspective top view of the earpiece 100 showing an azimuthAZ illustrating a first orientation of the audio output member 150relative to the first body 110, according to one embodiment. In FIG. 1E,the X-axis is represented by a horizontal line extending from an origin(i.e., X, Y, and Z=0) located at the three dimensional center 110C ofthe first body 110 when the earpiece 100 is oriented so that the centralportion 114C (see FIG. 1D) of the first body 114 is positioned at zeroin the X direction (i.e., the central portion 114C of the first body 114is disposed within an YZ plane). In FIG. 1E, the azimuth AZ is the anglebetween the X-axis and a first reference line XY′ in the XY plane (i.e.,Z=0). The first reference line XY′ passes through the same XYcoordinates as the end 166E of the sound tube 166. The azimuth AZ can beused to indicate the direction in an XY plane at which the end 166E ofthe sound tube is oriented relative to the X-axis extending from thecenter of the first body 110.

FIG. 1F is a perspective side view of the earpiece 100 showing analtitude ALT illustrating a second orientation of the audio outputmember 150 relative to the first body 110, according to one embodiment.The altitude ALT is the angle between the first reference line XY′ and asecond reference line XYZ′ that passes through the same XYZ coordinatesas the end 166E of the sound tube 166. Thus, the first reference lineXY′ and the second reference line XYZ′ both pass through the same XYcoordinates where the end 166E of the sound tube 166 is located anddiffer at these locations only by the Z-coordinate. Thus, the altitudeALT can be used to identify the vertical direction (i.e., Z-direction)at which the end 166E of the sound tube 166 is oriented relative to thefirst reference line XY′.

FIG. 1F also shows an initial angle 170 of the audio output member 150relative to the X-axis before the curing process is performed, defininghow the audio output member 150 is initially oriented in a verticaldirection. The initial angle 170 can be configured with a startingorientation of the audio output member 150 that more closely matches theangle of a user's ear canal across a broad population of users or asubset of the broader population. In some embodiments, the initial angle170 can be between 10 and 50 degrees, such as 30 degrees.

In some embodiments, the audio output member 150 is oriented in the XYplane relative to a stationary first body 110 such that the azimuth AZ(FIG. 1E) in an earpiece 100 is set to one of many desired orientationsso that the configured orientation of the audio output member 150 in ahorizontal plane is able to fit a particular user. In other words, anearpiece 100 may be originally formed such that the audio output member150 is configured in one of many pre-set discrete angular orientationsso as to fit many different groups of the human population. In otherembodiments, the audio output member can move (e.g., rotate) in the XYplane relative to a stationary first body 110 before the curing processis performed allowing the user to adjust the audio output member 150 toa proper and comfortable orientation in the user's ear canal beforecuring the curable filler material 116.

In some embodiments, during the curing process the azimuth AZ may beadjusted by about 45 degrees in either direction relative to a startingorientation of the audio output member 150. For example if the startingorientation is set at an azimuth AZ of 50 degrees relative to theX-axis, then the azimuth AZ may be adjusted between 5 degrees and 95degrees relative to the X-axis.

Furthermore, in these embodiments, the audio output member 150 may alsobe flexible in the vertical direction such that the altitude ALT (FIG.1F) may be adjusted during the curing process enabling the user toadjust the orientation of the audio output member 150 in a verticalplane. In some embodiments, the altitude ALT may be adjusted by about 45degrees in either direction relative to a starting orientation of theaudio output member 150. For example if the starting orientation is setat an altitude ALT of 70 degrees relative to the first reference lineXY′, then the altitude ALT may be adjusted between 25 degrees and 115degrees relative to the first reference line XY′.

FIG. 2A is an exemplary illustration of a human outer ear 200. Theearpiece 100 is configured to conform to portions of a user's outer ear200 for a snug and comfortable fit. A description of these portions ofthe outer ear 200 follows and is useful for understanding how theearpiece 100 conforms to a user's outer ear 200 in subsequent portionsof this description.

The outer ear 200 includes an ear canal 202 leading to an ear drum (notshown). Ear lobe 201 forms a lower portion of the outer ear 200 and ahelix 206 extends from the ear lobe 201 to a top portion of the outerear 200. The ear canal 202 is surrounded by the cavum conchae 203, thecrus helix 205, the tragus 210, and the antitragus 212. The cavumconchae 203 has a recessed shape (e.g., bowl shape) relative to thesurrounding portions of the outer ear 200 other than the ear canal 202.The earpiece 100 can be placed in this recessed shape of the cavumconchae 203 as more fully described below. The antitragus 212 is aprojection extending from the ear lobe 201 towards the ear canal 202.The tragus 210 is a projection extending from the face (not shown)towards and/or over the ear canal 202. The crus helix 205 is a spinyportion extending from above the tragus 210 to the cavum conchae 203.The antihelix 208 is disposed between the helix 206 and the crus helix205. The antihelix 208 is separated from the crus helix 205 by the cymbaconchae 204, which is recessed relative to the crus helix 205 and theantihelix 208. The portion of the antihelix 208 that is connected to thecymba conchae 204 is the crus antihelicis inferioris 214. The portion ofthe antihelix 208 that extends to the helix 206 is the crus antihelicissuperioris 216.

FIG. 2B is a perspective view of the earpiece 100 disposed within aportion of the outer ear 200 before a user customizes the earpiece 100to conform to the shape of the user's outer ear 200 during the curingprocess, according to one embodiment. In FIG. 2B, the audio outputmember 150 is disposed at least partially in the ear canal 202. Thefirst body 110 is disposed against the cavum conchae 203 and the cymbaconchae 204 straddling the crus helix 205. The flexible tail 135 isdisposed in the cymba conchae 204 being positioned to press against orproximate to a wall 204W (see FIG. 2C) of the cymba conchae 204 thatleads to the crus antihelicis inferioris 214.

FIG. 2C is a perspective view of the earpiece 100 disposed within aportion of the outer ear 200 after a user customizes the earpiece 100 toconform to the shape of the user's outer ear 200 during the curingprocess, according to one embodiment. The user can customize theearpiece 100 to conform to the shape of the user's outer ear 200 bypressing the first body 110 against at least portions of the cavumconchae 203 and the crus helix 205, so that the first body 110 laterallyexpands until portions of the first body 110 contact portions of one ormore of the tragus 210 and a wall 203W of the cavum conchae 203 opposingthe tragus 210. The first body 110 can also contact the crus helix 205and portions of the cymba conchae 204, such as a wall of the cymbaconchae 204.

In FIG. 2C, the audio output member 150 is disposed at least partiallyin the ear canal 202, and the first body 110 is disposed against thecavum conchae 203 and the cymba conchae 204 straddling the crus helix205. The flexible tail 135 is disposed in the cymba conchae 204 beingpositioned to press against the wall 204W of the cymba conchae 204 thatleads to the crus antihelicis inferioris 214. During the customizationprocess (e.g., curing process), the flexible tail 135 can be presseddeeper into the cymba conchae 204 and can align with the profile of thewall 204W of the cymba conchae 204 leading to the crus antihelicisinferioris 214 after the first body 110 has been deformed.

The orientation of the audio output member 150 relative to the firstbody 110 can be adjusted due to the flexible connection created betweenthe first body 110 and the audio output member 150. Thus, theorientation of the audio output member 150 can be adjusted to a desiredorientation in three dimensions relative to the first body 110. Theflexible connection can be created by adjusting the shape andcross-sectional area of the first connection location 111 (FIG. 1A-1B)and type of material(s) used to form the outer body 114 and outer shell151. For example, in one embodiment, a thickness of the flexibleconnection at the first connection location 111 can be from about 3 mmto about 10 mm, such as between about 3.3 mm and about 9.6 mm, such asabout 6.3 mm. In one example, the cross-sectional area of the firstconnection location 111 is between about 9 mm² and about 30 mm² toachieve a desired flexibility/stiffness at the first connection location111 found between the first body 110 and the audio output member 150.Furthermore, in some embodiments, the flexible connection at the firstconnection location 111 can have a circular cross-section, so that thethickness is uniform throughout the flexible connection. In oneconfiguration, the audio output member 150 is coupled to the first body110 at a flexible connection that is positioned therebetween as, forexample, illustrated in FIGS. 1A and 1B. In one embodiment, thecross-sectional area being the area that is shared by the adjoiningmaterial of the outer body 114 and outer shell 151 is positioned at thefirst connection location 111. Thus, the audio output member 150 can beoriented comfortably within the user's ear canal 202 before the firstbody 110 is customized to the user's outer ear 200, and not apply asignificant load or strain on portions of the user's ear after thecustomization process has been performed. The orientation of the audiooutput member 150 relative to the first body 110 can change when thefirst body 110 is customized to conform to the user's outer ear 200. Forexample, portions of the first body 110 will generally laterally expanddownward towards the antitragus 212, which can cause portions of theaudio output member 150 to move downward in a corresponding fashion. Asportions of the audio output member 150 move downward, the ear tip 155can adjust its orientation relative to the base 157 of the audio outputmember 150, so that the ear tip 155 maintains a comfortable fit in andapplies a minimal load to the user's ear.

In some embodiments, the orientation of the audio output member 150relative to the first body 110 can be locked in place after the curablefiller 116 is cured when the user customizes the earpiece 100 to theuser's outer ear 200. Locked in place, herein refers to an orientationthat the audio output member 150 has when there are no external stressesare applied to the audio output member 150 relative to the first body110. Thus, the orientation of the audio output member 150 relative tothe first body 110 may still be flexible in three dimensions after thecurable filler 116 of the first body 110 is cured, but the stress-freeorientation of the audio output member 150 is set during the curingprocess.

In some embodiments, the audio output member 150 can be connected to thefirst body 110 or a portion of the earpiece 100 between the first body110 and the audio output member 150 by a joint (e.g., a ball joint, notshown). In some embodiments, the joint can allow the audio output member150 to rotate 360 degrees relative to the first body 110. In someembodiments including a joint, the first body 110 may be configured sothat a portion of the curable filler 116 expands into the ball jointwhen the first body 110 is deformed by the user to conform to the user'souter ear 200, so that the orientation of the audio output member 150relative to the first body 110 is locked into place as described abovewhen the curable filler 116 is cured. In other embodiments, a fillersimilar to the curable filler 116 can be placed in the joint, so thatthe joint can allow free movement before the filler in the joint iscured. The filler in the joint may be during a portion of the curingprocess and/or cured by the same method as the curable filler 116 iscured, such as a UV cure process. After the filler in the joint iscured, the orientation of the audio output member 150 relative to thefirst body 110 can be locked in place as described above.

FIG. 2D is a perspective view of the earpiece 100 further illustratingthe effects of customizing the earpiece 100 to a user's ear during thecuring process, according to one embodiment. In FIG. 2D, the first body110 deforms from an original shape (shown as first body 110 ₁ includingouter body 114A₁) to a deformed shape (shown as first body 110 ₂including outer body 114A₂) after the user has conformed the earpiece100 to the user's ear by use of the steps described in FIG. 3 below.During the customization process, the flexible tail 135 can move from afirst position and orientation (shown as flexible tail 135 ₁) to asecond position and orientation (shown as flexible tail 135 ₂), due tothe load applied to the bladder 115 and outer body 114 of an undeformedfirst body during the curing process. The customized flexible tail 135 ₂has moved upward relative to the original flexible tail 135 ₁, so thatthe customized flexible tail 135 ₂ can press against portions of theuser's ear, such as the wall 204W of the cymba conchae 204 describedabove in reference to FIG. 2C.

Furthermore, the audio output member 150 can move from a first positionand orientation (shown as audio output member 150 ₁ of an undeformedfirst body) to a second position and orientation (shown as audio outputmember 150 ₂), due also to the load applied to the bladder 115 and outerbody 114 during the curing process. As illustrated in FIG. 2D, thecustomized audio output member 150 ₂ has moved downward relative to theoriginal audio output member 150 ₁. For example, the outer shell 151 andear tip 155 have each moved downward from a first position (shown asouter shell 151 ₁ and ear tip 155 ₁) to a second position (shown asouter shell 151 ₂ and ear tip 155 ₂). Although FIG. 2D shows the outershell 151 and the ear tip 155 moving downwards relative to theiroriginal positions, the actual movement of the outer shell 151 and theear tip 155 can depend on the shape of a given user's ear. In someembodiments, the ear tip 155 of the audio output member 150 can bepushed deeper into the ear canal 202 (see FIG. 2A) of the user as aresult of the customization process, further improving the secureness ofthe fit of the earpiece 100 in the user's ear.

FIG. 3 is a process flow diagram of a method 1000 for customizing theearpiece of FIG. 1A to a user's ear, according to one embodiment. Themethod 1000 is also referred to herein as generally the curing process.Although the method steps are described in conjunction with the systemsof FIGS. 1A-2D, persons skilled in the art will understand that anysystem configured to perform the method steps, in any order, is withinthe scope of the present invention.

Referring to FIGS. 1A-3, the method 1000 is described. At block 1002,the user places the audio output member 150 of the earpiece 100 in theuser's ear canal 202. For example, the user can place the audio outputmember 150 in the user's ear canal 202 by orienting the end 155E of theear tip 155 to be positioned at the entrance of the user's ear canal 202and then pushing the ear tip 155 into at least a portion of the user'sear canal 202 and slightly towards the user's ear drum (e.g., see theposition of the audio output member 150 in FIG. 2B). The end 166E of thesound tube 166 can be substantially facing the user's ear drum (notshown) when the ear tip 155 is positioned into the user's ear canal 202.The base 157 of the audio output member 150 can be facing away from theuser's outer ear 200 when the ear tip 155 is positioned into the user'sear canal 202.

In some embodiments of block 1002, the user may select an earpiece 100that has an audio output member 150 that is initially positioned at anazimuth AZ angle that closely matches a measured or known angle of auser's ear canal. In other embodiments, it is desirable to select anearpiece 100 that has an audio output member 150 that is initiallypositioned at an azimuth AZ angle that is aligned in a direction that isoff-center or non-collinear with an axis of the ear canal so that whenthe azimuth AZ angle is adjusted during the curing process, a morealigned position with the axis of the ear canal is achieved.

At block 1004, the user places the first body 110 against the user'scavum conchae 203 and cymba conchae 204, so that the first body 110straddles the crus helix 205 (e.g., see the position of the first body110 in FIG. 2B).

At block 1006, the user places the flexible tail 135 in the cymbaconchae 204 so that it can be pressed against the wall 204W (see FIG.2C) of the cymba conchae 204 that leads to the crus antihelicisinferioris 214.

At block 1008, the user applies a force or load to the first body 110 topress and urge the first body 110 against portions of the user's outerear 200, such as the cavum conchae 203, the cymba conchae 204, and thecrus helix 205. For example, the user's hand may be used to press and/orurge the first body 110 against these portions of the outer ear 200. Thepressure applied by the user causes the elements in the first body 110to deform and laterally expand, so that a larger portion of the firstbody 110 contacts one or more of the cavum conchae 203, the cymbaconchae 204, the crus helix 205, and the tragus 210. The earpiece 100can be more suitably retained in the user's outer ear 200 after theflexible material within first body 110 expands to contact a largersurface area of the user's outer ear 200, such as a larger surface areaof one or more of the cavum conchae 203, the cymba conchae 204, the crushelix 205, and the tragus 210. The increased surface area of contactbetween the first body 110 and the user's outer ear 200 increasedfriction between the earpiece 100 and the user's outer ear 200, whichimproves the ability to retain the earpiece in the user's ear.

During block 1008, the load applied to the first body 110 will cause thebladder 115 and outer body 114 to distort in a YZ plane (e.g., Y andZ-directions in FIG. 1D). The applied load thus causes the dimensions(e.g., diameter) of the bladder 115 and ring 114A in the Y-Z plane (FIG.1D) to increase as the user urges the first body 110 against the user'souter ear 200 (e.g., load is applied in the X-direction). The distortionof the bladder 115 and ring 114A then cause the flexible tail 135 andoutput member 150 to move relative to the first body 110, as discussedabove in relation to FIG. 2D, due to the stress induced in these membersdue to the applied load. Thus, in some embodiments, it is desirable toadjust the cross-sectional shape of the ring 114A and concave feature1146 and material properties of the materials used therein to controlthe amount of movement of the flexible tail 135 and change in theazimuth AZ angle after performing method 1000.

At block 1010, the energy source 120 is activated to cure the curablefiller 116 while the load that is applied during block 1008 to deformthe first body 110 is maintained. For example, in one embodiment, theenergy source 120 is a UV light source that is activated for arecommended time period (e.g., 60 seconds), so that the deformed curablefiller 116 can be cured and thus fixed in the deformed orientation.Curing the curable filler 116 enables the first body 110 to retain itsshape after the user removes the applied force during block 1008 and theearpiece 100 is removed from the user's outer ear 200. Also, in someembodiments curing the curable filler 116 can assist in maintaining theorientation of the audio output member 150 relative to the first body110. For example, the audio output member 150 may be less adjustable inone or more dimensions relative to a stationary first body 110 afteractivating the energy source 120 to cure the curable filler 116.Furthermore, in some embodiments curing the curable filler 116 may alsohelp maintain the position and orientation of the flexible tail 135relative to the first body 110 in a relatively fixed orientation.

Therefore, due to the configuration of the bladder 115 and outer body114 components described herein, and the use of flexible and curablematerials used to form these elements, the final orientation of theoutput member 150, flexible tail 135 and shape of the first body 110 canbe adjusted and fixed to better suit and match a user's ear. Therefore,a custom-fit earpiece that includes features providing superiorretention in a user's ear while also maintaining desirable comfort andsound quality is formed.

While the foregoing is directed to embodiments of the presentdisclosure, other and further embodiments of the disclosure may bedevised without departing from the basic scope thereof, and the scopethereof is determined by the claims that follow.

What is claimed is:
 1. An earpiece for providing sound to a usercomprising: a first body comprising a bladder and a curable fillerdisposed within the bladder; and an audio output member comprising asound tube, wherein the audio output member is coupled to the first bodyat a flexible connection that is positioned therebetween, and the audiooutput member is positioned outside of an exterior surface of thebladder.
 2. The earpiece of claim 1, wherein an orientation of the audiooutput member is adjustable in two dimensions relative to the firstbody.
 3. The earpiece of claim 1, further comprising an audio driverdisposed within the audio output member and coupled to the sound tube.4. The earpiece of claim 3, further comprising: one or more signalprocessing components that are electrically coupled to the audio driver;and a transceiver that is electrically coupled to the one or more signalprocessing components, and is configured to provide a signal that isreceived from an external electronic device to the one or more signalprocessing components.
 5. The earpiece of claim 1, wherein the flexibleconnection is positioned at a first location on the first body, and theearpiece further comprises a flexible tail coupled to the first body ata second location on the first body.
 6. The earpiece of claim 5, whereinthe second location is at least 90 degrees apart from the first locationon the first body.
 7. The earpiece of claim 1, wherein the curablefiller is a photopolymer.
 8. The earpiece of claim 1, wherein theearpiece further comprises a UV light source.
 9. The earpiece of claim1, further comprising an outer body disposed around the bladder, whereinthe outer body includes a central portion that extends around thebladder, the bladder consists of a first portion and a second portion,the first portion disposed entirely on a first side of the centralportion of the outer body and the second portion disposed entirely onthe second side of the central portion of the outer body, and the secondportion comprises at least 40% of a total volume of the bladder.
 10. Theearpiece of claim 9, wherein the bladder has a shape of a sphere and thefirst portion and the second portion are each a hemisphere of thesphere.
 11. The earpiece of claim 9, further comprising a flexible tailcoupled to the outer body at a second location on the outer body. 12.The earpiece of claim 11, wherein the second location is at least 90degrees apart from the first location of the first body.
 13. A method ofcustomizing an earpiece for use in an outer ear of a user, comprising:placing an audio output member comprising a sound tube in an ear canalof a user; placing a first body in a cavum conchae of an outer ear ofthe user, wherein the first body comprises a bladder and a curablefiller disposed in the bladder, the audio output member is coupled tothe first body at a flexible connection that is positioned therebetween,and the audio output member is located outside of an exterior surface ofthe bladder, and applying a force to the first body to press the firstbody against the cavum conchae, wherein the force causes the first bodyto deform.
 14. The method of claim 13, further comprising activating anenergy source to cure the curable filler.
 15. The method of claim 13,wherein placing the first body in the cavum conchae further comprisesplacing the first body in a cymba conchae of the outer ear of the userso that the first body straddles a crus helix of the outer ear of theuser.
 16. The method of claim 13, further comprising placing a flexibletail against a wall of a cymba conchae of the outer ear of the user,wherein the flexible connection is positioned at a first location on theouter body, and the flexible tail is coupled to the first body at asecond location.
 17. The method of claim 16, wherein applying force tothe first body to press the first body against the cavum conchae causesthe flexible tail to conform to the wall of the cymba conchae.
 18. Themethod of claim 16, wherein the second location is at least 90 degreesapart from the first location.
 19. The method of claim 13, wherein theorientation of the audio output member is less adjustable in one or moredimensions relative to the stationary first body after activating theenergy source to cure the curable filler.
 20. A method of forming acustomized earpiece, comprising: positioning an earpiece within aportion of an ear of a user, wherein the earpiece comprises a first bodythat comprises an outer body supporting a bladder, and an audio outputmember that is coupled to the outer body of the first body at a firstlocation, and wherein positioning the earpiece comprises: positioning asound tube of the audio output member in an ear canal of the ear of theuser, and the first body in a cavum conchae of the ear of the user;urging the first body against the cavum conchae, wherein urging thefirst body against the cavum conchae causes the bladder and the outerbody to deform and an angular orientation of the audio output memberrelative to the ear canal to adjust; and curing a curable fillermaterial disposed within the bladder while urging the first body againstthe cavum conchae, wherein curing the curable filler material comprisesdelivering one or more wavelengths of electromagnetic radiation to thecurable filler material from an energy source to cause the bladder andthe outer body to be fixed in the deformed state.